Fluid flow monitor and control system

ABSTRACT

A fluid flow monitoring, evaluation, and control system providing accurate dispensing of fluids in low volume, high pressure systems. The system includes one or more fluid flow sensors mounted on positive displacement dispensing valves and a processor that receives cycle signals from the fluid flow sensors to determine fluid flow information. If the fluid flow is not within specified limits, a signal is sent to a pump control device to adjust the pump to return the fluid flow to desired level. A dispensing valve can include a display to show cycle time or other fluid flow measurement. The system can include dispensing valves having single inputs and single outputs for measuring fluid dispensed at a point of use, which measurement can be compared to measurements taken at a divider block earlier in the hydraulic path to verify that fluid sent into the path was actually dispensed.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.10/402,205, filed Mar. 26, 2003, which is a continuation of U.S. patentapplication Ser. No. 10/383,920, filed Mar. 7, 2003 and now abandoned,which is a continuation-in-part of U.S. patent application Ser. No.10/176,385, filed Jun. 20, 2002 and now issued as U.S. Pat. No.6,823,270, which claims priority from U.S. Provisional Pat. App. No.60/299,851 filed. Jun. 20, 2001. All earlier applications are herebyincorporated by reference.

TECHNICAL FIELD OF THE INVENTION

The present invention relates to the field of fluid flow monitoring,analysis, and control and, in particular, to methods and apparatuses forintegrated monitoring, analysis, and control of low volume, highpressure fluid flow systems.

BACKGROUND OF THE INVENTION

A variety of fluids, such as lubricants and chemical reactants, are usedin modern industry. For example, compressors and other machines reduceinternal friction between parts by injecting a lubricant, such as oil orgrease, into critical bearing surfaces and reciprocating part junctions.If the flow of lubricant is interrupted, compressors and otherindustrial tools can be seriously damaged or destroyed. On the otherhand, too much lubricant can unnecessarily increase the operatingexpenses of the machinery and can contaminate the environment. Poorlycontrolled fluid flow can affect the result in other industrialoperations, such as well bore components, gas pipeline components, andoil and gas production.

A variety of systems are used to distribute lubrication in industrialmachine applications. Originally, multiple pumps were used to supply oilto multiple points. It was found that, in such systems, the flow was notsufficiently uniform between lubrication points, with some points beingstarved for lubricant while other points wasted lubricant with excessiveflow.

A more reliable system uses a pump to pressurize a fluid distributionline and a positive displacement divider block, also referred to as adivider valve, to distribute a lubricant, such as oil, from the singlepump outlet line to multiple injection points. A typical divider blockis operated by the pressure of the incoming fluid to divide the fluidinto multiple output channels. Divider blocks typically include multipleinternal pistons that are activated by the flow of the incoming oil. Asthe oil moves the pistons, internal hydraulic circuits open and close todistribute a known volume of lubricant to each of the multiple outputsfor each cycle of the pistons. Because the internal hydraulic circuitsare progressively opened and closed by the flow of the incoming oil, noexternal power source is required to operate the divider block, and noexternal timing signal is required to deliver a prescribed amount of oilto each outlet line. The bore and stroke of each piston determines theamount of fluid delivered with each cycle of the divider block. Becausethese dimension are known, the amount of oil distributed for each cycleof the divider block can be readily calculated, and if the number ofcycles in a unit of time is tracked, the flow rate can be readilydetermined. The simplicity and reliability of divider blocks have leadto their wide acceptance in many applications.

Divider blocks can still fail to provide adequate lubrication in somecircumstances. For example, a pump failure can reduce the inlet flow tothe divider block, reducing the amount of lubricant distributed. Thedivider block can become clogged, jammed, or sufficiently worn so as toreduce fluid or lubrication flow to specific points.

U.S. Pat. No. 5,835,372 to Roys et al. for an “Integrated Fluid FlowEvaluation Apparatus and Method,” which is hereby incorporated byreference, describes a system for monitoring the cycles of the outputsof a divider block. In accordance with the Roys et al. patent, a fluidflow sensor can be mounted at an outlet position of a divider block todetect cycles of the combined outlets. The sensor includes a magnet,typically mounted on a rod coupled mechanically or magnetically to thepiston. The magnet moves back and forth as the piston moves. A reedswitch positioned along the path of the magnet is operated as the magnetpasses, so each signal from the reed switch corresponds to a cycle ofthat dispensing valve piston. Knowing the bore and stroke of the piston,the system can determine the lubricant flow rate, e.g., the number ofpints per day, at an outlet by counting how many times the reed switchcloses during a measured time period. For example, if the piston expels10 cc of lubricant with each cycle and the reed switch closes threetimes each minute, a lubricant flow of 30 cc/min should pass throughthat outlet of the divider block. Since all pistons of a divider blockgo through one complete dispense process during each period that thevalve cycles, a user typically connects a single sensor to one outlet ofthe divider block to count valve cycles, and then infers the fluid flowfrom all the outlets.

A fluid flow monitor associated with the sensor includes amicroprocessor that counts reed switch activations and a display mountedon the monitor to provide control information to field personnel. Themonitor can also send a signal to shut down the lubricated equipment ifthe flow of lubricant is below a minimum level. Although stored data isprimarily viewed in the field by maintenance personnel, the monitor canbe connected to a central control panel.

While the system of Roys et al. displays some control information ateach divider block, a field service technician is typically required toread the information from each monitor display to check the status andhistory of that individual block. Although a “hard-wired” control panelnear the divider block can be used to collect data from multiplesensors, running wires adds to the cost of installation and may bedifficult or impossible in some situations, such as in areas containingexplosive gases or at long distances from the control panel. In manyapplications a field maintenance operator cannot electrically downloadinformation from a monitor on-site, because in an explosive hazardenvironment, it is forbidden to make or break electrical connectionsbecause of the possibility of causing a spark.

Also, although the Roys et al. system provided information about thefluid that exited the divider block, it provides no information aboutwhether the fluid actually reached the injection point. Thus, leaksbetween the divider block and the injection point can go undetected.

Relatively small volume fluid flow is not typically measured in-linebecause of a lack of cost-effective measuring equipment. Turbine-typemeasurement devices are used in fluid systems having a high volume offluid flow, for example, measured in gallons per minute or liters perminute. Turbine devices are not suitable for measuring low volume, thatis, in the range of about ten gallons or less per day. Such low volumesare typically pumped by lubrication and chemical pumps. Positivedisplacement pump-type measuring systems typically use gears and aretypically expensive and cannot accurately measure low volumes. Suchdevices are impractical to use in large numbers to monitor fluid flow atthe large number of points necessary to characterize fluid flow in alarge system and they are typically not sufficiently accurate at lowvolumes. Accurate measurement of the flow of relatively small amounts offluid at the relatively high pressure used in some systems has been aproblem in the industry.

In the oil and gas industry, the amount of fluid used in manycircumstances is determined by observing a “draw down” gauge at a tank.Such gauges are not precise, and while such gauges indicate the amountof fluid that left the tank, they do not directly measure the fluid thatwas applied at the injection point. Leaks or wrongly set valves mayprevent fluid that left the tank from arriving at its intended injectionpoint. The lack of a practical method of monitoring the divider blockfor measurement, trending and control of fluid.

The accuracy of fluid flow measurement based on a cycle counter on adivider block can decrease over time. As the divider block wears overhundreds of thousands or millions of cycles, the amount of fluiddelivered for each cycle of the piston can vary, with some of the fluidbypassing the piston and traveling to a point of least resistance. Then,some lubricant flows back around the piston instead of being forced intothe outlet, and the flow calculations based on the piston size to eachlubrication point or fluid injection point become inaccurate.

U.S. Pat. No. 6,212,958 to Conley describes the use of a blade thatextends into the pipe and the degree of deflection of the blade as fluidflows is an indication of fluid flow. Extending a blade into the fluidcan affect the fluid flow and the blade can deteriorate over time.

Another solution to measuring fluid flow has been to use a thermistor toinfer fluid flow based upon a change in temperature. This method is onlyfor monitoring movement of fluid and cannot monitor in quantity offluid. Such units are expensive, are impractical to attach to a largenumber of fluid flow points to accurately monitor and characterize alarge system and are not permitted in areas where explosive gases orvapors are present. There are sometimes disagreements between suppliersand users about the amount of fluid that has been delivered.

When fluid flow is monitored, using the devices described above, theinformation available has been limited primarily to current flow and hasbeen used primary to shut down equipment or to sound an alarm. Thisinformation is typically inadequate for precise monitoring. For example,when a single compressor in a multiple compressor system fails, it wouldbe difficult to detect that the failure was caused by an intermittentlubrication problem, particularly if the lubrication system wasfunctioning adequately at the time of failure. Service personnel wouldlikely observe that the other compressors are satisfactory and determinethat the lubrication system is operating properly and assume that thefault was in the compressor itself. In fact, the lubrication system maybe operating properly at the time the technician observes the system,but a previous undetected problem may have damaged the compressor to thepoint where it fails later, when it is receiving adequate lubrication.Thus, it has been very difficult to diagnose some lubrication problemsand such problems cost industry a great deal in ruined equipment.

SUMMARY OF THE INVENTION

An object of the invention is to provide a method and apparatus formonitoring and controlling fluid flow so as to detect and correctinadequate or excessive flow and thereby minimize damage to machineryand the environment and reduce operational cost.

The present invention comprises a system for monitoring, analyzing, andcontrolling fluid flow. In one embodiment, the system comprises one ormore fluid flow monitors that determine fluid flow from cycle countsfrom one or more fluid flow sensors attached to dispensing valves. Thedispensing valves can distribute fluid to multiple output channels, thatis, the dispensing valve can be a divider valve, or the dispensingvalves can distribute fluid to a single output channel. A single outputdispensing valve and an associated sensor can be used to measure anddisplay average valve cycle time or fluid flow within a hydraulicchannel, such as at an injection point. A fluid flow monitor can bemounted directly on the dispensing valve or be positioned away from thedispensing valve and accept remote input by wire or radio frequency linkfrom a fluid flow sensor that is mounted on a dispensing valve. Thefluid flow monitor system can store fluid flow information, which can bedownloaded, for example, by an infrared link, to a personal digitalassistant or a personal computer. The fluid flow monitor system can alsooutput a signal to a pump control device to adjust the pump if the fluidflow is not within specified guidelines. The fluid flow monitor systemcould also output a local alarm signal or a machine shutdown signal whencomparison of the fluid flow with programmed parameters indicates aproblem. Data from the fluid flow monitor or cycle information fromfluid flow sensors can be transmitted via a satellite radio link to aserver computer for transmitting over or posting on the Internet,allowing the data to be accessed at locations remote from the locationof the fluid flow monitor. In some embodiments, measured fluid flowvalues can be compared with desired fluid flow values and adjustmentscan be made from any point in the world with access to the Internet,automatically or by manual data entry, to a pump to bring measuredvalues close to desired values.

Another aspect of the inventive system includes the use of a Hall effectsensor to detect motion of a piston follower in a fluid flow sensor.

Another aspect of the invention entails the ability to download datafrom a fluid flow monitor using an infrared link, thereby allowinginformation to be downloaded in a safe manner in an explosiveenvironment without having to hard wire connections to the monitor.

Another aspect of the invention includes the ability to convert fluidflow data from a personal digital assistant data format to a format thatis useable in commercially available software, such as spreadsheets anddatabases, suitable for analyzing information.

Another aspect of the inventive system is a fluid flow sensor in whichthe magnet and spring assembly is constrained within a housing when thesensor is not connected to the dispensing valve, thereby preventingthese components from falling out when the sensor is installed orremoved.

Another aspect of the invention provides a feedback loop between thefluid measuring device and a fluid pump, so that the fluid pump can beadjusted to increase or decrease the fluid flow, thereby preventingexcess fluid flow, which can, for example, waste resources, andpreventing insufficient fluid flow, which can, for example, damageequipment for lack of adequate lubrication.

The foregoing has outlined rather broadly the features and technicaladvantages of the present invention in order that the detaileddescription of the invention that follows may be better understood. Thesystem as described herein includes several inventive aspects, and notall embodiments will include all the features described. Moreover, itshould be appreciated by those skilled in the art that the conceptionand specific embodiment disclosed may be readily utilized as a basis formodifying or designing other structures for carrying out the samepurposes of the present invention. It should also be realized by thoseskilled in the art that such equivalent constructions do not depart fromthe spirit and scope of the invention as set forth in the appendedclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present invention and theadvantages thereof, reference is now made to the following descriptionstaken in conjunction with the accompanying drawings, in which:

FIG. 1 is a block diagram of a preferred fluid flow evaluation system.

FIG. 2 shows a multistage compressor having two fluid flow monitors eachmounted directly on a dispensing valve and each capable of transmittingflow information through an infrared link, and alarm and shut-downinformation via wire to a local control panel and then optionallythrough a satellite link to the Internet.

FIGS. 3A-3H are typical input screen images from a personal digitalassistance that interfaces with a fluid flow monitor.

FIG. 4 shows a multistage compressor having two fluid flow monitorsmounted on a control panel and receiving piston cycle signals from fluidflow sensors mounted on dispensing valves, the fluid flow monitorsproviding alarm and fluid trend information locally and optionally via asatellite link to the internet.

FIG. 5 shows a multistage compressor having two fluid flow monitorsmounted on a control panel and receiving piston cycle signals via radiofrequency links from fluid flow sensors mounted on dispensing valves,the fluid flow monitors providing alarm and fluid trend informationlocally and via a satellite link to the internet.

FIG. 6 shows a multistage compressor having a single fluid flow monitormounted on a control panel and receiving piston cycle signals via aradio frequency link from multiple fluid flow sensors mounted atinjection points on the compressor, the fluid flow monitor providingalarm and fluid trend information locally and via a satellite link tothe internet.

FIG. 7 shows schematically a wireless injection point assembly formeasuring fluid flow and transmitting the information to a fluid flowanalyzer.

FIG. 8 shows multiple injection point assemblies of FIG. 7 connected viawireless links to a single fluid flow monitor.

FIG. 9 shows schematically a fluid monitor having a wireless receiverfor receiving information from the wireless injection point assembly ofFIG. 7.

FIG. 10 shows a fluid flow monitor having an internal Hall effect fluidflow sensor.

FIG. 11 shows an enlarged view of the fluid flow sensor of FIG. 10.

FIG. 12 shows roughly the magnetic flux lines around the magneticassembly of FIG. 11.

FIG. 13A shows a fluid flow sensor having a contained magnet and a reedswitch. FIG. 13B shows the housing of the fluid flow sensor of FIG. 13A.FIG. 13C is an exploded view of the components of the fluid flow sensorof FIG. 13A. FIG. 13D is an exploded view of the components of a fluidflow sensor similar to that of FIG. 13A, but using a Hall effect sensorinstead of a reed switch.

FIGS. 14A-14D show a fluid dispensing valve having a single input and asingle output.

FIG. 15 shows a multi-stage compressor having fluid flow sensors mountedat multiple injection points on the compressor, each of the fluid flowmonitors including a liquid crystal display for indicating cycle time.

FIG. 16 is a combination block diagram and flow chart showing thecomponents and steps of a system that automatically adjusts fluid flowbased upon fluid flow measurements.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 shows a block diagram of a preferred fluid flow evaluation system8. Fluid flow evaluation system 8 includes a fluid flow monitor 9, suchthe Proflo® fluid flow monitor from C.C. Technology, Inc., Midland,Tex., the assignee of the present invention. Fluid flow monitor 9includes a microcontroller 10, such as a Hitachi H8/3847microcontroller, a memory 12, such as a 64k EEPROM, and an outputdisplay 14, such as a liquid crystal display.

Microcontroller 10 accepts input signals from a fluid flow sensor, theinput signals corresponding to piston cycles. A fluid flow sensor 22 canbe located within fluid flow monitor 9. That is, the fluid flow monitor9 can be mounted directly on a dispensing valve, and the internal fluidflow sensor detects the movement of a magnet that is moved by adispensing valve piston. Alternatively, fluid flow monitor 9 can bemounted remotely from the dispensing valve being measured, and fluidflow monitor 9 can accept piston cycles signals transmitted via wire orradio frequency wireless link from a separate fluid flow sensor mountedon the dispensing valve.

The piston cycle signal received from the fluid flow sensor 20 or 22 iscombined by the fluid flow monitor 9 with clock signals and informationabout the amount of fluid flow per valve cycle to determine a flow rateof fluid. Different information can be stored in memory 12 dependingupon user requirements. For example, memory 12 can store individualcycle times, average cycles for a predetermined period, or somecombination of individual readings and average. Memory 12 preferablystores at least twelve months of operational data.

In a fluid flow sensor mounted on a dispensing valve, a magnet islinked, mechanically, magnetically, or otherwise, with a piston of thedispensing valve. As the dispensing valve cycles, the moving magnetprovides a magnetic “pulse,” which is detected by a reed switch or Halleffect sensor switch in the fluid flow monitor. A Hall effect sensoremits a low level signal that is detected and counted by themicrocontroller in the fluid flow monitor. The Hall effect sensor switchhas no moving parts and so will not wear out and will not be readilydestroyed by vibration. The fluid flow monitor 9 preferably can outputan alarm signal 44 and information 40 about valve cycles that correlateto fluid flow. The fluid flow monitor can also preferably shut down thecompressor if lubrication is inadequate.

The output 40 from the fluid flow monitor can be through a wire, throughan infrared link, such as an IrDA (Infra red data associate) link, orthrough a radio frequency satellite link using, for example, the RS 485standard. Fluid flow monitors are often located in areas of extremeexplosion hazard, such as around explosive chemicals or natural gas. Insuch environments, connecting or disconnecting electrical circuitspresents an extreme hazard because of the risk of generating a spark. Byusing an infra-red link, the present invention allows a person todownload fluid flow data in a safe manner in an explosive environment.Although the data could also be downloaded by hard-wired electricalconnections, such connections are more costly to provide, particularlyto retrofit into existing equipment.

Different information can be output differently from the same fluid flowmonitor. For example, an alarm signal or a shut-down signal 44 may beoutput along a wire to a control panel, whereas fluid flow trendinformation may be output through the infrared link to a hand-heldcomputer or through a radio frequency satellite link. If a satellite ortelephone link is used, the information can then be automatically madeavailable through the Internet to equipment owners and operatorsanywhere in the world. Alarm conditions can be relayed to designatedindividuals via paging, telephone, e-mail, instant messaging, web siteposting or other Internet or non-Internet notification.

FIG. 2 show a multistage compressor 202 lubricated by a fluid deliveredfrom a fluid pump 204 to two dispensing valves 206. Each of dispensingvalves 206 dispenses lubricating fluid to multiple lubrication fourinjection points 208 on the compressor 202. Attached to at least oneoutput of each of the valves dispensing 206 is a fluid flow monitor 210.Each fluid flow monitor 210 includes an internal cycle switch, such as aHall effect sensor or a reed switch, that is activated by a magnet thatmoves in coordination with the corresponding piston (not shown) withindispensing valves 206. The cycle switch provides indication signals thatare combined by microprocessor 10 with timing signals to determine fluidflow information, which is stored in memory 12.

The fluid flow monitor system of FIG. 2 is also wired to an alarm 240 ona control panel 242 to provide an alarm signal when a programmable alarmcondition, such as an inadequate or excessive lubrication flow, areencountered. A shut down signal can also be transmitted to the controlpanel 242 to shut down compressor 202 if the fluid flow level coulddamage the compressor. An alarm signal can also be transmitted from thecontrol panel 242 via satellite link 246 to a network server that makesthe alarm available to a user over the World Wide Web or other computernetwork.

Information about fluid flow can be downloaded from the fluid flowmonitors on the dispensing valves by an infrared link 250 to a portablecomputing device, such as a personal digital assistance (PDA), forexample, a Palm Pilot or Handspring Visor. A personal digital assistancemay be usable in an explosion-rated environment because of the lowbattery voltage, whereas a notebook or laptop computer may not beprohibited. Moreover, using an infrared link to download informationeliminates the need to make a temporary electrical connection betweenthe computing device and the fluid flow monitor 210, thereby allowingdata to be transferred in an explosion-rated environment where suchconnections are prohibited. The system of FIG. 2 allows the operator toeasily and immediately begin protecting and monitoring the fluid flow inthe system.

FIGS. 3A-3H are examples of screens displayed on a PDA forcharacterizing fluid flow. FIG. 3A shows an opening screen whendisplayed the fluid control application is begun. FIG. 3B shows theapplications that are available from a pull-down command menu. FIG. 3Cshows divider block data that is displayed when “Divider Block DailyData” is selected from Command menu. The Divider Block Daily Data screendisplays, for each hour period during the day, the average cycle timefor the divider clock and the amount of lubricant injected.

FIG. 3D shows a screen that allows the user to readily locate periods ofunder lubrication or over lubrication. The user can enter parameters todefine what constitutes over or under lubrication. Such conditions canendanger the compressor or waste lubricant and the invention allows suchconditions to be readily identified and repaired. FIG. 3E shows theinformation displayed when a “Divider Block History” is requested. FIG.3F shows a screen that allows the user to transfer data to or from thefluid flow monitor. Several help screens are available to assist users.For example, FIG. 3G shows a help screen that explains to users how todetermine the total flow through a divider block. FIG. 3H shows a set-upscreen used to program limits for initiating warning and systemparameters such as alarm time, divider block totals, recommended cycletime, and bus address for data communication. Screens 3A-3H are exampleof typical screens and different screens may be used to enter or displayother information. Information from the portable computing device may betransferred to another computer and converted into a format usable bycommercially available analysis programs, such as Microsoft Excel orAccess.

FIG. 4 shows a multistage compressor system 400 similar to that shown inFIG. 2, with a different embodiment of the fluid flow evaluation systemconnected thereto. In the fluid flow evaluation system of FIG. 4, fluidflow monitors 404 are mounted on a control panel 405 away from thedivider blocks 406 so a technician need not go to each divider block 406to download fluid flow data. Fluid flow sensors 408 are mounted on thedivider block 406 to detect piston cycles using, for example, a reedswitch or a Hall effect sensor. Piston cycle information is transmittedover wires 420 from the fluid flow sensors 408 to the fluid flowmonitors 404. As in the previous embodiment, the piston cycle signalsare combined in fluid flow monitors 404 with timing signals to determinefluid flow information and the information is stored in the memory.

The fluid flow information in memory can be downloaded to a portablecomputing device over an infrared link 250 as in the embodiment of FIG.2, so that information can be transferred in a hazardous environment.The fluid flow monitor 404 can send a signal to alarm 240 whenprogrammed alarm conditions prevail and can also output a shut downsignal when necessary to protect the compressor. The alarm and fluidflow information can also be transmitted to a satellite or othercommunications link 450 so that the fluid flow data is accessible inremote locations, preferably over the World Wide Web or other computernetwork.

FIG. 5 shows a multistage compressor system 500, similar to those in theprevious FIGS. Like the embodiment in FIG. 4, fluid flow monitors 510are mounted away from divider blocks 505. In the system of FIG. 5,however, radio frequency transmitters 512 transmit cycle signals fromfluid flow sensors 504 at divider blocks 505 to the fluid flow monitors510. By eliminating the requirement to run wires, installation,particularly in a retrofit situation, is greatly simplified and the costis reduced. Wireless transmitters 512 can be powered by a battery or bya solar energy source. Wireless receivers 514 at fluid flow monitors 510can also be powered by a battery or by a solar energy source, or thewireless receiver could be powered by a power line. As with the systemof FIG. 4, the piston cycle signals are combined by monitors 510 withtiming signals to determine fluid flow information and the informationis stored in the memory. The memory information can be downloaded to ahandheld device over infrared links 250. Fluid flow monitor 510 canproduce an alarm signal causing alarm 240 to sound when programmed alarmconditions prevail and can also output a shut down signal when necessaryto protect the compressor.

The alarm and flow information can also be transmitted to a satellite orother wireless communications link 450 so that the alarm information orfluid flow data is accessible in remote locations. The data can be madeavailable over the World Wide Web or other computer network. Thewireless link of the FIG. 5 system allows the monitor to be remotelymounted in a place that is easily accessible and to receive piston cyclesignals from all injection points.

FIG. 6 shows a system similar to that of FIG. 5, but includes at eachinjection point a single outlet divider block 601 to inject a fixedquantity of fluid. A fluid flow sensor 602 is mounted on each singleoutlet divider block 601 to measure the exact amount of fluid dispensedat each injection point. Each fluid flow sensor 602 has an associatedwireless transmitter 604 for sending fluid flow information to a singlefluid flow monitor 610 positioned on a control panel 612. A receiver 614associated with the fluid flow monitor 610 periodically polls eachtransmitter 604 to obtain piston cycle information and converts thepiston cycle information to fluid flow information for each injectionpoint 208. By measuring fluid flow at each injection point 208, theactual fluid injected is measured, regardless of whether fluid is lostbetween the divider block 603 and the injection point 208. When eachdivider block 601 cycles, a known quantity of oil has been dispensed.

Fluid flow monitor 610 receives and translates piston cycle informationfrom all transmitters 604 and translates the piston cycles tointelligible data for accurate fluid flow. Thus, a single receive 614can monitor hundreds of injection points and provide accurateinformation about quantities of lubricant, chemical or fluid.

To measure fluid flow at the insertion point, a preferred fluid flowsensor entails a dispensing valve having a single-input and a singleoutput. The single output dispensing valve operates in a manner similarto that of a conventional divider block, but the dispensing valvedispenses fluid at a single outlet. Thus, a known amount of lubricant isoutput for each cycle of the pistons and, by sensing piston cycles asdescribed above, the amount of lubricant dispensed can be readilydetermined. This single-input single output-divider valve is a positivedisplacement valve. This valve is suitable for measuring at relativelyhigh pressures very small to extremely small quantities, such as a fewcubic inches per day in one embodiment, about 14.0 cubic inches inanother embodiments and up to about 10 gallons per day in yet anotherembodiment. Prior art fluid flow measuring devices were either notsuitable for accurately measuring flows in this flow range and pressureor were of complex, geared construction too expensive for use in suchapplications.

FIGS. 14A-14D shows a single input, single output dispensing valve.Although having a single output, such a dispensing valve can also bereferred to generally as a type of divider block. FIG. 14A shows an endview of a dispensing valve 1402 having two cylinders 1404 positionedabove a third cylinder 1406. FIG. 14B shows the interior of dispensingvalve 1402. FIG. 14B shows a lower piston 1410 in cylinder 1406 and oneof upper pistons 1412 in one of the two upper cylinders 1404. Upperpistons 1412 move together. Fluid enters through one of the uppercylinders 1404, moves to a bottom cylinder 1406, and then out ofdispensing valve 1402 through an upper cylinder 1404. Skilled personscan readily design pistons and a hydraulic path suitable for variousapplications. FIG. 14C shows a cross section of single input, singleoutput dispensing valve 1402 with an attached fluid flow sensor 1430having electrical connections for conveying cycle signals to a remotefluid flow monitor. (Dispensing valve 1402 is shown rotated in FIGS. 14Cand 14D so that the lower piston 1412 is shown facing the viewer, andupper pistons 1412 are partially hidden.) The FIG. 14D shows dispensingvalve 1402 attached to a fluid flow monitor 1440 that is internal to afluid flow monitor 1442.

In some implementations, aspects of the embodiments of FIGS. 6 and 5 arecombined so that fluid flow is measured at both the dispensing point andthe injection point. By measuring at both places, leaks between the twopoints can be detected, thereby reducing environmental damage andreducing wasted fluid. Any combination of fluid flow sensors can beused.

Systems that use a radio frequency transmitter or receiver tocommunication piston cycles preferably have a battery indicator so thatthe battery can be replaced before it fails. Otherwise, properlyfunctioning equipment may shut down because no piston cycles aredetected by fluid flow monitor 250.

FIG. 7 shows in more detail a wireless injection point assembly 702comprised of two principle sub-assemblies: a wireless transmitting unit708 and an injection point unit 709. Injection point unit 709 iscomprised of an injection device 711, such as single output dividerblock 601 or multiple outlet divider block 505 described above, coupledwith a fluid flow sensor 710, such as sensor 602 described above.Whenever a fluid pulse is delivered out of injection device 711, theelectrical contacts of switch 710 are cycled one time.

Transmitting unit 708 is comprised of a radio frequency (RF) transmitter731, a microcontroller 732 executing control software stored in memory713, a power supply 733, a battery 734, interface circuitry 735, and anantenna 736. An optional photovoltaic system 740 can supply power forwireless transmitting unit 708.

Contact closures of fluid flow sensor 710 are passed to microcontroller732 via an interface 735 that converts the output signal from switch 735into a signal compatible with the input of microcontroller 732.Microcontroller 732, operating in accordance with software in memory713, counts the contact closures received from fluid flow sensor 710.

FIG. 8 shows the larger environment in which one or more wirelessinjection point assemblies 602 operate. A local system 817 includes areceiver unit 814 in communication with a fluid flow monitor 815,preferably a Proflo® from C.C. Technology, Inc. Receiver unit 814received data from the one or more wireless injection point assemblies712. Each wireless transmitter 712 has a unique identifier and isprovided a unique address so that receiver unit 814 can associateincoming date with the appropriate one of wireless injection pointsystems 712.

Each contact closure recorded causes microcontroller 732 to generate amessage containing an identifier value, which uniquely identifies thespecific wireless injection point assembly 712, and a count valuecorresponding to switch closures. This message is formatted fortransmitting to the receiver unit 814 working within local system 817.The sending units will send a count to the receiver unit that in turn isused to determine fluid flow, based on the known volume per injectioncycle, to a desired accuracy, for example, to 1/100th of a pint.

This information is stored in the fluid flow monitor 815 to betransmitted to the end user via wireless download to a PDA handheld andto any earth orbiting satellite to connect to the Internet for access bythe operator. Time sequencing between pulses of units 712 are determinedby the master divider block and collected by the fluid flow monitor orsatellite communication device to be transmitted at any given time tothe owner/operator or user of the pump or compressor. In a preferredembodiment, different ones of injection point assemblies 712 on the samedivider block will not pulse at the same time due to the master dividerblock system utilizing progressive in-line movement of each piston as itmoves oil. This sequencing assures that no two injection pointassemblies 712 will transmit data at the same time, and therefore avoidsthe possibility, of a collision of messages and possible failure ofreceiver unit 814 to receive data being sent by one or more of theinjection point assemblies 712.

FIG. 9 shows receiver unit 814 in more detail. Receiver unit 814includes an antenna 916 for receiving transmission from wirelesstransmitting unit 708, a radio frequency receiver 918, a microcontroller919 in communication with a memory 920 for storing program instructionsfor controlling the operation of receiver 814, and an interface 930 forcommunication with fluid flow monitor 815. Receive unit 814 alsoincludes a power supply 921 for supplying appropriate voltage andcurrent to components within receive unit 924, a battery 926 forsupplying power to power supply 921 when necessary, and an optionalphotovoltaic system 928 for supplying power to power supply 921.

All information relating to fluid flow is optionally communicated to thereceiving unit 814 and transferred by wireless transmitters (not shown)to satellite receivers for viewing on the Internet on secure web sites.This data will inform the operator of any problems with the quantity ofoil injected to each lubrication point of the compressor. Alllubrication points will have set parameters that will be monitored andstored by the Proflo® wireless system.

In some embodiments, a display can be associated with each injectionvalve. The display can be integral with or attached to the dispensingvalve. The display is typically a liquid crystal display that displaysthe valve average cycle time in seconds. An average of six cycles istypically used to provide a more consistent, meaningful measurement,although a different number of cycles could be averaged or individualcycle times could be displayed. The injection valve or an attachedmodule incorporates, besides the display itself, a Hall switch or reedswitch to activate the LCD counter and indicate each cycle. Anintegrated circuit times the cycles and computes average cycle times. Aninternal battery powers the LCD and associated circuitry.

FIG. 15 shows a multi-stage compressor 1502 that includes multipledispensing valves 1504 at multiple lubricant injection points, eachdispensing valve 1504 having an associated liquid crystal display 1506.The cycle time in seconds is displayed for each dispensing valve. Inother embodiments, the LCD counter can be mounted remote from thedispensing valve so as to enable the operator to more easily see thecycle time of the valve. The capability to mount the LCD remote from thedispensing valve time addresses any safety concerns about operatorsneeding to climb over and around the compressor or chemical pump toobserve cycle times of the injection point.

Providing the capability to manually monitor the cycle time of theinjection valve allows the operator to immediately and inexpensivelyidentify potential system problems, such as the injection of too much ortoo little lubrication in a compressor, or too much or too littlechemical injected in a processing system. A practical method ofidentifying oil consumption in low volume, high pressure, eithermechanically or electronically to each injection point is not currentlyavailable in the industry. If there are, for example, ten lubricationpoints on the compressor, the operator can easily install a dispensingvalve on each point and manually monitor each point to ensure thecorrect amount of lubrication is being injected into each point.

To determined from the displayed flow rate the quantity of oil orchemical injected into each point, the operator uses the followingformula: P=6×V/S, where P is the flow rate in pints per day, V is thevolume of fluid dispensed each time the dispensing valve cycles onetime, and S is the time required for one complete cycle of thedispensing valve. The constant, 6, results from converting cubic inchesof fluid to pints and seconds to days.

For example, if the LCD on the dispensing valve indicates an 11 secondcycle time, and the volume output of the dispensing valve is 0.030 cubicinch per cycle, 6×30/11, that is, 16.4 pints per day are being injectedthrough the valve.

By displaying only the cycle time and allowing the operator to determinethe actual flow rate, the same measurement device can be used ondifferent valves having different volumes. Alternatively, theelectronics associated with the display can calculate and display a flowrate, for example, in pints per day, based on a preset or programmablevolume and the measured cycle time. As used herein, the term “fluid flowinformation” includes not only rate information, but any information,such as cycle time, from which a rate can be determined.

In some embodiments, a fluid flow monitor of the present invention canuse a Hall effect sensor switch. Hall effect sensors detect the presenceof or change in a magnetic field. Hall effect switches operate as binaryswitches, with the switch state being turned on when the magnetic fieldrises above a prescribed value and being turned off when the magneticfield drops below a prescribed value. When positioned close to a magnet,Hall switches have difficulty detecting a small relative displacementbecause the change in magnetic field is very slight. FIG. 10 shows afluid flow monitor 1010 having an internal fluid flow sensor 1014 thatuses a Hall effect sensor 1016 mounted on the fluid flow monitor 1010for use, for example, in a system like that shown in FIG. 2. A fluidflow monitor having an internal fluid flow sensor can be mounted at adivider block or at an injection point. A fluid flow monitor can also bemounted away from a fluid flow sensor, with connection from the fluidflow sensor to the fluid flow monitor provided by wire or wirelessmethods.

FIG. 11 shows a fluid flow monitor sensor 1102 that comprises a housing1104, a magnetic assembly 1106 comprising two magnets 1112 separated bya non-magnetic spacer 1114. A hydraulically driven piston (not shown)pushes a non-magnetic, preferably stainless steel, piston follower 1116that moves magnetic assembly 1106 relative to Hall effect sensor 1118. Aspring 1120 biases the magnetic assembly 1106 against piston follower1116 and causes magnetic assembly 1106 to follow piston follower 1116when it moves away from magnetic assembly 1106.

The magnets are oriented such that the opposite poles face each otheracross the spacer, which is preferably composed of a 300 seriesstainless steel. In one embodiment, magnets 1112 are composed of Alnico5 alloy, have a strength of about 60 gauss, a diameter of 0.187 in, anda length of 1.0 inch. In this embodiment, non-magnetic spacer 1114similarly has a diameter of 0.187 in, is preferably about 0.30 incheslong, and made of 304 stainless steel. The sensor switch 1118 itself is,for example, an Allegro Model A3210ELH operating at between 2.5 V and3.5 V, and rests on a printed circuit board 1128 that is positioned adistance 1130 of approximately 0.25 in away from the edge of housing1104.

The design of magnet assembly 1106 produces a region having a largechange in magnetic field over a small distance, thereby enabling theHall effect transistor 1118 to operate properly in close proximity tomagnetic assembly 1106, with minimal travel of the magnetic assembly1106. The travel of the piston in the divider block assembly isapproximately 0.125 inch. Prior art magnet assemblies that use a Halleffect sensors in close proximity to the magnet are unreliable becausethe change in the magnetic field corresponding to such short pistontravel is relatively small and difficult to reliably detect. By using aconfiguration that concentrates the magnetic flux, the magnetic field isdirected into a peak, which produces a magnetic field of approximately60 Gauss. When the magnets move 0.1.25 in, the magnetic field will dropto less than 10 Gauss. The change in magnetic field is readily andreliably detected by Hall effect sensor 602.

FIG. 12 shows a rough approximation of the magnetic flux lines 1202produced by magnet assembly 1106 and the preferred position of the Halleffect sensor 1118 within the magnetic field. Note that the sensor ispreferably positioned above one of the magnets 1112 and not in thecenter of the spacer 1114. The configuration of the two magnetsseparated by a non-magnetic spacer provides four regions in which themagnetic field changes rapidly in space. In one embodiment, the magneticfield can vary from about 60 gauss to about 10 gauss within about 0.125inch. This change in field over a small distance allows the use of arelatively low power, inexpensive sensor, such as the type typicallyused in cellular telephones, which require a change of about 50 gaussfor accurate detection. Using the above example as guidance, a skilledperson will be able to design a magnet assembly, either experimentallyor by using magnetic field modeling software, for different applicationsby varying the length of the spacer to achieve the required fluxgradient.

Another embodiment of a Hall effect sensor uses a single magnet with thesensor precisely centered over the magnet and positioned about onequarter of an inch away from it. The magnet is preferably composed ofAlnico 5 alloy because of the better symmetry of the magnetic fieldsaround such magnets. By positioning the Hall effect sensor preciselyabove the center of the magnet, the required change in magnetic field toactivate the Hall effect switch is achieved as the magnet is moved asmall distance, typically about one quarter of one inch, by the pistonfollower.

In some prior art fluid flow sensors used with a lubricant distributionblocks, the magnet, spring, and spacer have nothing to keep them in thehousing place-when the unit is removed from the dispensing valve. When atechnician removes the sensor housing from the distribution block, themagnet, spring, and spacer can fall from the housing and become lost,dirty, or damaged. The components must be thoroughly checked for damage,cleaned, and re-installed in the magnet housing. Any or contaminationinside the magnet housing will cause the movement of the parts to beinhibited, which will give erratic switch closures to monitoringequipment and cause phantom shutdown of the machinery being monitored.Phantom shutdowns and erratic monitoring cause the industry thousands ofdollars in lost revenue due to downtime of the machine. To solve thisproblem, some prior art fluid flow sensor units are sealed at thefactory and cannot be opened in the field to replace damaged components.This increases maintenance expenses by requiring the whole unit to bereplaced when an inexpensive component, such as a spring, breaks.

An inventive proximity switch eliminates the possibility of lost ordamaged components and introduction of dirt or foreign particles insidethe housing. In one preferred embodiment of a fluid flow sensor, theswitch components, such as the spring and magnets, are trapped inside ahousing so that the components cannot fall out when the switch isinstalled or removed, but the switch can be disassembled to remove thecomponents for repair, such as to replace a weak or broken spring.

FIG. 13A shows a fluid flow sensor 1302 that comprises a single pole,single throw magnetically operated reed switch 1303. A spring 1304,magnet 1306, spacer 1307, and pin 1308 are contained within a housing1309 by a threaded insert 1310 that prevents the loss of parts by aperson installing the unit on a dispensing valve.

FIG. 13B is an enlarged view of housing 1309 for fluid flow sensor 1302and FIG. 13C is an exploded view showing how the parts of fluid flowsensor 1302 are assembled. Fluid flow sensor 1302 includes withinstainless steel housing 1309 and magnet 1306, spring 1304, spacer 1307and pin 1308. Magnet 1306, spring 1304 and pin 1308 are contained insidethe threaded housing by stainless steel pin 1312 having a change indiameter along its length to produce a shoulder. Threaded insert 1310has a hollow hexagon passage and is screwed into housing 1309 using ahex-head wrench after the other components are inserted. The hexagonalpassage allows pin 1308 to slide in and out with cyclic movement of thefluid flow dispensing valve piston, but the shoulder, which cannot fitthrough the hollow passage in threaded insert 1310, prevents pin 1308(and therefore magnet 1306, spring 1304 and spacer 1307) from fallingout of the housing 1309. The spacer 1307 is connected to the spring 1304by a machined section, which snaps into the spring. Magnet 1306, spring1304 and spacer 1307 can be removed for repair by unscrewing pin 1308from housing 1309.

Fluid flow moves the cyclic piston located in the dispensing valve (notshown) which forces pin 1308 and magnet 1306 to move back and forth in alateral movement past the reed switch 1303 causing it to open and close.The reed switch sends a dry contact signal to a fluid flow monitor. Thefluid flow monitor can be used use with any control monitoring devicethat utilizes a dry contact switch closure to detect pulses or switchclosures. Such devices include all progressive in-line dispensing valvesthat disperse fluid for volumetric measurement.

Instead of the reed switch shown in FIGS. 13A-13C, a Hall effect sensorcould be used with an appropriate design of the magnets and housing.FIG. 13D shows an exploded view of fluid flow monitor 1012 of FIG. 11.As in the fluid flow sensor 1302, a threaded insert 1350 keeps thecomponents inside housing 1104.

The ease of downloading fluid flow, trending and alarm informationon-site by infrared data link to hand held computer devices or viasatellites from the site to the WWW allows a system of the presentinvention to greatly improve the efficiency of fluid flow systems. Fluidflow analysis software expedites understanding the downloaded fluid flowinformation and provides useful information to service personnel in easyto understand form. In some embodiments, “raw” cycle data is sent overthe Internet and is converted to more easily used fluid flow rateinformation at a site remote from the sensor. In other embodiments, thecycle signals are converted to flow rate, average cycle period, or otherinformation before being sent.

The use of this fluid flow monitor in any of these forms will give theoperator and industry a method of monitoring and trending fluid flownever before possible. This will save the industry hundreds or thousandsof dollars in lost revenue due to failed components caused by too littleor too much lubricant, chemical or fluid being injected into thecompressor, well bore, or mechanical device. This monitor will also savethe industry untold dollars in revenue due to wasted lubricants,chemicals or fluids harming the environment.

The software on the handheld computer device trends the use of fluid,thereby allowing instant knowledge of fluid use trends that can showchanges over time. Software for analyzing the downloaded information canbe used to show trends in the fluid flow, which can indicate problemsbefore they become critical, or indicate past problems, that may be ahidden cause of machinery failures.

The software preferably stores 365 days of fluid flow information. Thesoftware will also convert the fluid flow information to a standardapplication, such as Microsoft Excel spreadsheet, for custom analysis.The fluid flow file identifies the compressor to which the fluid flowsensor was connected, the technician responsible for the system, thedaily flow rates, over flows, under flows.

With remote mounting of a fluid flow monitor using radio frequency (rf)signals, monitoring every point using a master control box, and thenusing software for instant downloading and easily analysis ordownloading via satellite, the service personnel have ready access tomore information than ever before about fluid flow in small pumps andlubrication systems and oil flow through dispensing valves.

A fluid flow monitor can optionally include a global positioning systemthat indicates its position. When information is transmitted bysatellite, the position is also transmitted. A user can view theposition of the fluid flow monitor on a map, along with fluid flowinformation. Thus, service personnel can monitor fluid flow at a largenumber of points automatically. When an alarm condition occurs, theservice person can immediately see the geographical location of thesystem generating the alarm. Of course, the location of each fluid flowmonitor could also be programmed into the fluid flow monitor fortransmission with the data, obviating the use of the GPS system.However, by using the GPS option, the position is detectedautomatically, without depending on an individual to re-program thelocation when the fluid flow monitor is initially set up or moved.

By using radio frequency transmission between the fluid flow sensors andthe fluid flow monitors and then transmitting fluid flow information,including GPS information via satellite to a web site, installation ofthe system is greatly simplified and accuracy is improved. This allows auser to install systems to monitor a large number of fluid flow pointswith minimal installation and operation costs. By providing thisinformation, industry will save an enormous amount of money by reducingconsumption of excess fluid and by saving expensive equipment before itfails from lack of lubricant. For example, a large term reduction oflubricant may affect the longevity of a machine, even if the lubricanthas not decreased to an alarm level. Users can spot trends oflubrication use to detect problems before they significantly affect themachinery or fluid consumption. They can see latitude and longitude ofchemical pumps because the GPS unit is on site.

The invention typically measures with great accuracy a low volume, highpressure fluid flow at some point on the discharge side of a pump. Anintegrated system of the invention can measure fluid flow not only atthe output of dispensing valves that distribute fluid between multiplechannels, but alternatively or additionally, at one or more fluidinjection points. Thus the actual fluid delivered is measured and anydiscrepancy between the distribution dispensing valve flow data andinjection point flow data indicates a leak or a worn dispensing valve.The invention is “scalable” and can be implemented with a large numberof fluid flow monitors and measuring points.

The fluid flow monitor can be readily retrofitted to existinginstallations. The use of battery or solar powered radio frequency linksbetween the measurement point and the fluid flow monitor facilitateinstallation at a large number of measuring points and reduceinstallation costs. The use of a satellite link and Internet accessmakes the data accessible anywhere in the world. Thus, service personnelcan monitor fluid flow at any time of the day or night withoutdispatching an individual to the site to collect data from each of thefluid flow monitors.

The invention is particularly applicable to systems having fluid flow athigh pressures and low volumes. For example, systems having a fluid flowvolume of less than about 80 pints per day at a pressure of greater thanabout 500 psi. The invention can be used with fluid flows as low asabout 3 pints per day or lower and at pressures as high as 5,000 psi orhigher. A typical operating condition is about 8 pint per day at about3,000 psi. The fluid flow sensors of the present invention includepositive displacement pumps, operated by the pressure of the fluid beingprocessed, and the sensors operate on the discharge side of the fluidpump, thereby providing accurate information at low flow volumes andhigh pressure, and provide information about fluid flow near or at theactual point of fluid use. The volumes and pressures described aboveapply to sensors attached to single inlet, single outlet dispensingvalves as well as to sensors attached to multiple outlet divider valves.

The invention is suitable for monitoring and evaluating fluid flow oflubricant for machines, such as compressors and pumps, and forcontrolling the flow of fluids into well bores, pipelines, coolingtowers, etc. The invention will have a great economic impact,particularly in the oil and gas industry, and on the environment bycontrolling excessive or too little lubrication or chemical substancesinjected into compressors, well bores, pipelines, and several othercritical areas needing accurate flow monitoring and evaluation, as wellas immediate warning if flow volumes are outside of the specifications.

In one embodiment, the fluid flow monitor is in data communication,either via wire or wireless data transmission, directly or indirectly,with a control device that controls the fluid flow. As described withrespect to previous embodiments, switch closure information istranslated into fluid flow information. A microprocessor can be used tocompare the fluid flow information to known fluid flow requirements fora particular fluid flow system. Based on the comparison between themeasured fluid flow and the fluid requirements of the system, the fluidflow can be adjusted.

For example, an electromechanical control device can be mounted onto thefluid pump to adjust the fluid flow. In one embodiment, the controldevice turns an adjustment knob clockwise to lower the amount of fluidflow and counter clockwise to adjust the pump to inject more fluid. Thepump adjustment mechanism can be, for example, an integral part of apump, that is, the mechanism can be incorporated into the design of thepump, or the mechanism can be designed to be retrofitted to an existingpump. The pump being adjusted is typically a positive displacement, highpressure, low volume pump used to pump chemicals or lubricating oil. Amounting bracket adapted to the particular control device and pump canallow a technician to retrofit an existing pump in place of purchasing anew complete pump with the integral adjusting mechanism.

The microprocessor, which can be, for example, a stand alone processoror controller or part of a computer, compares the measured fluid flowwith the desired fluid flow and send adjustment signals can integratedinto a fluid flow monitor, such as the Proflo® device described above.The fluid flow monitor could be positioned, for example, at one of thepositions previously described, that is, by a dispensing valve as shownin FIG. 2 or at a central location as shown in FIGS. 4, 5, and 6. Themicroprocessor can also be located remote from the physical fluiddistribution system and information, such as switch closures, cycleperiod, flow rate, or fluid quantity, can be transmitted, such as bysatellite communications link, Internet, or a combination of satellitelink and Internet, to the microprocessor. The signal to adjust the fluidflow can be determined and transmitted fully automatically, that is,without operator intervention, or can require operator intervention.

After the fluid flow is increased or decreased, the fluid flow measuringdevice registers the changed fluid flow, and confirms that the fluidflow rate is correct. If the fluid flow is not correct, additionalsignals can be sent to adjust the flow rate. If the fluid flow measuringdevice indicates that after repeated attempts at adjustment, the fluidflow rate is still no correct, an alarm can sounded or a signal sent toa system operator to investigate. For example, a pump may be damaged andincapable of being adjusted to produce the required flow.

FIG. 16 is a combination flow chart and block diagram showing thecomponents and steps in a preferred embodiment. In step 1600, a fluidflow sensor 1602 senses a cycle and sends the cycle signal to a fluidflow monitor 1604. Fluid flow monitor counts cycles in step 1610 todetermine a fluid flow based on a known volume of fluid moved for eachcycle. In decision block 1612, the fluid flow rate is compared to adesired fluid flow rate, and in step 1614, a signal is sent to a pumpcontrol device if the flow rate is not within defined parameters. Inoptional step 1616, a system operator is notified that the flow rate isbeing adjusted. The notification can be, for example, via the Internet.As describe above, the function of the fluid flow monitor 1604 can beperformed locally or remotely, such as by a computer receiving cyclesignals and transmitting pump adjustment signals telephonically, overthe internet, via radio including satellite, or through some combinationof the above or other means.

In step 1620, a pump control device 1622 adjusts the pump flow, forexample, by rotating a control knob. Fluid flow sensor 1602 continues tomonitor the fluid flow, and the process repeats.

This automatic adjustment can eliminate the need for human interventionand allow equipment, such as a compressor lube oil pump or chemicalinjector, to maintain constant oil, chemical or other fluid flow.Continuous monitoring and automatic adjusting can save industry hundredsof thousands of dollars in excessive loss of oil, chemical or any typeof fluid which needs to be controlled to eliminate worn compressorparts, well bore or pipeline damage. The invention can also reduceenvironment damage caused by too little or too much fluid flow, forexample, when used in conjunction with the chemical injector pumps.

In one embodiment, all flow and adjustment information sent to theelectromechanical device is also transmitted to the Internet to enablethe owner/operator to monitor any adjustments of the pump. If the lubeoil or chemical pump cannot be adjusted to accommodate the fluid flownecessary to maintain the system integrity, the Proflo® monitor willimmediately send a warning message, via the Internet, as an alarm tonotify the owner operator of a malfunction of the system. The equipmentoperator can then send adjustment specification signals over theInternet to the Proflo® control monitor to adjust the pump manually fromany computer with WWW access.

The system described above includes many parts, some of which areoptional and some of which may be separately patentable. Not everyaspect of the invention need be included in every embodiment. The scopeof the invention is defined by the appended claims and is not intendedto be limited by the summary or detailed description, which are providedas examples. The term “fluid flow information” as used herein includesnot only fluid flow rates in volume per time, but also cycle signals,cycle period or frequency information, or other information that can becorrelated to fluid flow or consumption.

The invention has been described with respect to a lubricant andcompressor, but the invention can be used to measure any fluid,including for example, glycol or other chemicals. Skilled persons willrecognize that the components may need to be constructed from differentmaterials to resist corrosion when corrosive fluids are used. Theinvention has wide applicability for monitoring the use of chemicals ineveryday operation of oil and gas production equipment and gascompressors. Chemicals are commonly pumped into a well bore to increaseproduction. The invention can be used, for example, to ensure that thecorrect amounts of chemicals are injected, thereby optimizing the welloperation.

The invention is useful in any low volume fluid flow application, suchas chemical pumps, in which accurate measurements are requires,particularly where high pressures are used. The invention uses positivedisplacement pumps at low volumes and high pressures. Small pistons inpositive displacement pumps all the invention to accurately move andmeasure extremely small quantities of liquid, for example, as small as0.006 cubic inches, and to accurately trend use to 0.01 pint everythirty minutes.

It should be understood that various changes, substitutions andalterations could be made herein without departing from the spirit andscope of the invention as defined by the appended claims. Moreover; thescope of the present application is not intended to be limited to theparticular embodiments of the process, machine, manufacture, compositionof matter, means, methods and steps described in the specification. Asone of ordinary skill in the art will readily appreciate from thedisclosure of the present invention, processes, machines, manufacture,compositions of matter, means, methods, or steps, presently existing orlater to be developed that perform substantially the same function orachieve substantially the same result as the corresponding embodimentsdescribed herein may be utilized according to the present invention.Accordingly, the appended claims are intended to include within theirscope such processes, machines, manufacture, compositions of matter,means, methods, or steps.

1. A low volume, high pressure fluid dispensing system comprising: apump for pumping a low volume of fluid at a high pressure; a pumpadjustment device for adjusting the fluid flow from the pump; one ormore fluid flow dispensing valves operated by the system fluid pressureto dispense less than 80 pints per day of lubricant at a pressure ofgreater than 500 psi, wherein the low volume of the fluid dispensingsystem is less than 80 pints per day of lubricant, and wherein the highpressure of the fluid dispensing system is greater than 500 psi; one ormore fluid flow sensors, each associated with one of the one or morefluid flow dispensing valves, for measuring the fluid flow through thecorresponding dispensing valve, the fluid flow sensor producing signalscorresponding to fluid flow dispensing valve cycles; and a processorprogrammed to receive fluid flow information corresponding to fluid flowthrough the one or more fluid flow dispensing valves and to send asignal to the pump adjustment device to adjust the fluid flow from thepump if the fluid flow through the dispensing valve is not within apredetermined range, thereby allowing the fluid flow to be adjusted toprevent inadequate or excessive fluid flow.
 2. A low volume, highpressure fluid dispensing system comprising: a pump for pumping a lowvolume of fluid at a high pressure; a pump adjustment device foradjusting the fluid flow from the pump; one or more fluid flowdispensing valves operated by the system fluid pressure to dispenselubricant to lubricate a natural gas compressor, wherein the low volumeof the fluid dispensing system is less than 80 pints per day oflubricant, and wherein the high pressure of the fluid dispensing systemis greater than 500 psi; one or more fluid flow sensors, each associatedwith one of the one or more fluid flow dispensing valves, for measuringthe fluid flow through the corresponding dispensing valve, the fluidflow sensor producing signals corresponding to fluid flow dispensingvalve cycles; and a processor programmed to receive fluid flowinformation corresponding to fluid flow through the one or more fluidflow dispensing valves and to send a signal to the pump adjustmentdevice to adjust the fluid flow from the pump if the fluid flow throughthe dispensing valve is not within a predetermined range, therebyallowing the fluid flow to be adjusted to prevent inadequate orexcessive fluid flow.
 3. A low volume, high pressure fluid dispensingsystem comprising: a pump for pumping a low volume of fluid at a highpressure; a pump adjustment device for adjusting the fluid flow from thepump; one or more fluid flow dispensing valves operated by the systemfluid pressure, wherein the low volume of the fluid dispensing system isless than 80 pints per day of lubricant, and wherein the high pressureof the fluid dispensing system is greater than 500 psi; one or morefluid flow sensors, each associated with one of the one or more fluidflow dispensing valves, for measuring the fluid flow through thecorresponding dispensing valve, the one or more fluid flow sensorsincluding one or more positive displacement pumps that dispenses a fixedquantity of fluid each cycle and producing signals corresponding tofluid flow dispensing valve cycles; and a processor programmed toreceive fluid flow information corresponding to fluid flow through theone or more fluid flow dispensing valves and to send a signal to thepump adjustment device to adjust the fluid flow from the pump if thefluid flow through the dispensing valve is not within a predeterminedrange, thereby allowing the fluid flow to be adjusted to preventinadequate or excessive fluid flow.
 4. A low volume, high pressure fluiddispensing system comprising: a pump for pumping a low volume of fluidat a high pressure; a pump adjustment device for adjusting the fluidflow from the pump; one or more fluid flow dispensing valves operated bythe system fluid pressure, wherein the low volume of the fluiddispensing system is less than 80 pints per day of lubricant, andwherein the high pressure of the fluid dispensing system is greater than500 psi, the one or more fluid flow dispensing valves including adispensing valve having multiple outlets for dividing incoming fluidbetween multiple paths; one or more fluid flow sensors, each associatedwith one of the one or more fluid flow dispensing valves, for measuringthe fluid flow through the corresponding dispensing valve, the fluidflow sensor producing signals corresponding to fluid flow dispensingvalve cycles; and a processor programmed to receive fluid flowinformation corresponding to fluid flow through the one or more fluidflow dispensing valves and to send a signal to the pump adjustmentdevice to adjust the fluid flow from the pump if the fluid flow throughthe dispensing valve is not within a predetermined range, therebyallowing the fluid flow to be adjusted to prevent inadequate orexcessive fluid flow.
 5. The low volume, high pressure fluid dispensingsystem of claim 4 in which the pump, the pump adjustment device, the oneor more fluid flow dispensing valves, and the one or more fluid flowsensors are located at an equipment site and further comprising acommunications link connecting the fluid dispensing system at theequipment site to a computer network.
 6. The low volume, high pressurefluid dispensing system of claim 5 in which the communications linkconnects the fluid dispensing system to a computer network including aserver computer programmed to make fluid flow information available on aglobal computer network.
 7. The low volume, high pressure fluiddispensing system of claim 5 in which the processor is located remotelyfrom the equipment site and communicates with the fluid flow system atthe equipment site through the communications link.
 8. The low volume,high pressure fluid dispensing system of claim 4 in which the pump, thepump adjustment device, the one or more fluid flow dispensing valves,the one or more fluid flow sensors, and the processor are located at anequipment site.
 9. The low volume, high pressure fluid dispensing systemof claim 2 in which communications link connects the fluid dispensingsystem to a computer network including a computer programmed to receivesignals corresponding to fluid flow dispensing valve cycles, todetermine fluid flow rates based upon the signals, and make fluid flowinformation available on a global computer network.
 10. The low volume,high pressure fluid dispensing system of claim 4 in which the processoris programmed to receive fluid flow information in the form of signalscorresponding to individual cycles of the one or more fluid flowdispensing valves and to derive fluid flow rate information from thecycle signals or in which the processor is programmed to receive fluidflow rate information derived from multiple signals corresponding tocycles of the one or more fluid flow dispensing valves.
 11. The lowvolume, high pressure fluid dispensing system of claim 4 in which atleast one of the dispensing valves includes three pistons operated bythe pressure of the fluid being dispensed.
 12. The low volume, highpressure fluid dispensing system of claim 4 in which at least one of thedispensing valves includes internal pistons displaced by the fluid andin which the sensor detects the motion of the pistons by detecting achange in position of a magnet moving in coordination with the pistons.13. The low volume, high pressure fluid dispensing system of claim 4 inwhich the processor is programmed to send without operator interventiona signal to the pump adjustment device.
 14. The low volume, highpressure fluid dispensing system of claim 4 in which the processor isprogrammed to send without operator intervention a signal to the pumpadjustment device automatically.
 15. The low volume, high pressure fluiddispensing system of claim 4 in which the one or more fluid flowdispensing valves dispense lubricant to lubricate a machine.
 16. A lowvolume, high pressure fluid dispensing system comprising: a pump forpumping a low volume of fluid at a high pressure at a high pressure; apump adjustment device for adjusting the fluid flow from the pump; oneor more fluid flow dispensing valves operated by the system fluidpressure, wherein the low volume of the fluid dispensing system is lessthan 80 pints per day of lubricant, and wherein the high pressure of thefluid dispensing system is greater than 500 psi; one or more fluid flowsensors, each associated with one of the one or more fluid flowdispensing valves, for measuring the fluid flow through thecorresponding dispensing valve, the fluid flow sensor producing signalscorresponding to fluid flow dispensing valve cycles; and a processorprogrammed to receive fluid flow information corresponding to fluid flowthrough the one or more fluid flow dispensing valves and to send asignal to the pump adjustment device to increase the fluid flow from thepump if the fluid flow through the dispensing valve is below a specifiedvalue, thereby allowing the fluid flow to be adjusted to preventinadequate or excessive fluid flow and preventing damage to equipmentfrom a lack of lubrication.
 17. The low volume, high pressure fluiddispensing system of claim 16 in which the pump adjustment devicecomprises an electromechanical device.
 18. The low volume, high pressurefluid dispensing system of claim 16 in which the pump adjustment deviceis externally attached to the pump, thereby allowing the pump adjustmentdevice to be retrofitted to an existing pump.
 19. The low volume, highpressure fluid dispensing system of claim 16 in which the pumpadjustment device is an integral part of the pump.
 20. The low volume,high pressure fluid dispensing system of claim 16 further comprising anetwork interface by which the processor transmits a notification over acomputer network if the fluid flow through the dispensing valve is notwithin the predetermined range.
 21. The low volume, high pressure fluiddispensing system of claim 16 in which the one or more fluid flowdispensing valves includes a dispensing valve having a single inlet anda single outlet.
 22. The low volume, high pressure fluid dispensingsystem of claim 16 in which the processor is programmed to send a signalto the pump adjustment device to decrease the fluid flow from the pumpif the fluid flow through the dispensing valve is above a specifiedvalue, thereby eliminating wasted lubricant.
 23. A low volume, highpressure fluid dispensing system comprising: a pump for pumping a lowvolume of fluid at a high pressure; a pump adjustment device foradjusting the fluid flow from the pump; one or more fluid flowdispensing valves operated by the system fluid pressure, wherein the lowvolume of the fluid dispensing system is less than 80 pints per day oflubricant, and wherein the high pressure of the fluid dispensing systemis greater than 500 psi; one or more fluid flow sensors, each associatedwith one of the one or more fluid flow dispensing valves, for measuringthe fluid flow through the corresponding dispensing valve, the fluidflow sensor producing signals corresponding to fluid flow dispensingvalve cycles; a processor programmed to receive fluid flow informationcorresponding to fluid flow through the one or more fluid flowdispensing valves, to convert the cycle signals to measured fluid flowinformation, and to send a signal to the pump adjustment device toadjust the fluid flow from the pump if the fluid flow through thedispensing valve is not within a predetermined range, thereby allowingthe fluid flow to be adjusted to prevent inadequate or excessive fluidflow; and a communications link for sending fluid flow information to acomputer and posting the information on the Internet.